Building panel assembly for attaching fluted decks to underlying support structures

ABSTRACT

A building panel assembly has a first end support, a second end support, and an intermediate support positioned in spaced parallel relationship to each other, a deck positioned on the supports and having a plurality of low flutes extending across the deck in transverse relationship to the end supports, a plurality of fasteners affixed in the low flutes for securing the deck to the first end supports and a plurality of fasteners affixed in the low flutes of the deck so as to secure the deck to intermediate support. The fasteners used to attach the deck to the intermediate support are of a fewer number than the fasteners used to attach the deck to the end supports.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT

Not applicable.

INCORPORATION-BY-REFERENCE OF MATERIALS SUBMITTED ON A COMPACT DISC

Not applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to building panel assemblies. More particularly, the present invention relates to fluted decks that are secured to underlying support structures. Additionally, the present invention relates to fastening techniques for securing the deck section to end supports and intermediate supports.

2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 37 CFR 1.98.

In the construction of modern buildings, there is erected a steel skeleton. It is necessary to have floors in the buildings. The floors are generally concrete floors. The steel buildings often have steel roofing. In the construction of these buildings, the steel skeleton has steel beams. Steel panels are placed on the steel beams so as to form the roofing of the building. It is necessary to definitely position the steel panels with respect to each other. These steel panels are typically in the form of fluted decking. In other words, this fluted decking is formed of corrugated sheets of steel. Each of the sheets of steel has a high flute and a low flute. On one side of the sheet, there is an upright edge. On the other side of the sheet of steel, there is an envelope to receive the upright edge of the adjacent sheet of steel. The adjacent steel panels are bonded together, typically by a manually-operated crimping tool. The operator actuates the crimping tool and makes a dent in each side of the envelopes of the steel form and also in the upright edge of the next adjacent steel panel. The dent definitely positions the panels with respect to each other. The welder tack welds the panels to the underlying beam so as to position the panels onto the beam.

During the formation of roofing, it is important that the joints are secured together so as to prevent one panel from lifting off the other. It is often important to prevent the panels from shifting laterally with respect to each other along the beam. In view of the inherent forces created by wind, it is important to place the panels on the underlying beam structure in such a manner so as to withstand the forces imparted by wind and also to satisfy the shear strength requirements for the roofing. Ultimately, the roof section must be joined together with sufficient integrity to prevent the panels from separating from each other or shifting laterally under the presence of strong shear forces.

In the past, techniques have been provided whereby the fluted decking is joined to the end supports and the intermediate supports of the building. Typically, the fluted decking is laid upon such end supports and intermediate supports. Fasteners are secured in the low flutes of the fluted decking so as to fasten the low flutes directly to the top surface of the underlying end supports and intermediate supports. In typical practice, the same number of fasteners are applied so as to join the fluted decking to the end supports as the number of fasteners used to join the fluted decking to the intermediate support. The side laps of the adjacent decks are joined together through various connection techniques, such as welding or penetrating clinch connections.

U.S. Pat. No. 7,021,108, issued on Apr. 4, 2006 to the present inventor, shows a punching tool for connecting the side laps of the decking sections together. This punching tool includes a frame, a die fixedly and non-pivotally supported by the frame, a punch arm pivotally mounted on the frame, a mating die affixed to the punch arm, and an actuator interconnected to the punch arm. The punch arm is movable between a position in which the mating die engages the die and a second position in which the mating die is spaced from the die. The actuator serves to move the mating die between the first and second positions. A handle is connected to the frame and extends outwardly therefrom. The tool has surfaces for holding inserts, such as male and female dies. The male die has a generally triangular cross section. The female die has a generally inverted V-shaped configuration. The die include a plurality of female dies arranged in spaced-apart linear alignment and generally transverse to a longitudinal axis of the frame. The cooperation of the dies will create a “snake bite” cut in the adjoining sections of steel flooring, roofing and decking.

U.S. Pat. No. 6,990,781, issued on Jan. 31, 2006 to the present inventor, discloses a decking assembly having a first deck section with a male leg and a second deck positioned adjacent to and in overlapping relationship to the first deck section. The second deck section has a female leg overlying the male leg of the first deck section. The male leg and the female leg have a triangular tab formed therethrough such that the triangular tab extends outwardly on one side of the female leg so as to secure the edges of the sections together in secure relationship. A plurality of triangular tabs are formed in spaced relationship to each other.

It is an object of the present invention to provide a building panel assembly that effectively positions fluted decking onto end and intermediate supports.

It is another object of the present invention to provide a building panel assembly that minimizes the number of fasteners required so as to properly withstand shear forces.

It is a further object of the present invention to provide a building panel assembly whereby the steel fluted deck can be used as a shear element in buildings.

It is still another object of the present invention to provide a building panel assembly which improves the efficiency of building panel installation.

These and other objects and advantages of the present invention will become apparent from a reading of the attached specification and appended claims.

BRIEF SUMMARY OF THE INVENTION

The present invention is a building panel assembly comprising a first end support, a second end support in generally spaced parallel relationship to the first end support, an intermediate support positioned between the end supports and in spaced parallel relationship thereto, a deck positioned on the end supports and the intermediate support, a plurality of first fasteners securing the deck to the first end support, a plurality of second fasteners securing the deck to the second end support, and a plurality of third fasteners securing the deck to the intermediate support. The deck has a plurality of low flutes extending in parallel relationship to each other and extending across the deck in transverse relationship to the first and second end supports. The plurality of first fasteners are affixed in the low flutes of the deck. The plurality of second fasteners are also affixed in the low flutes of the deck. The plurality of third fasteners are further affixed in the low flutes of the deck. In the present invention, the plurality of third fasteners is fewer in number than the number of the first fasteners or the number of second fasteners.

In the present invention, the plurality of first fasteners are affixed in each and every one of the plurality of low flutes of the deck. Similarly, the plurality of second fasteners are affixed in each and every one of the plurality of low flutes of the deck. The plurality of third fasteners are affixed in every other low flute of the plurality of flutes of the deck. In the preferred embodiment of the present invention, the deck has seven low flutes. The plurality of third fasteners is a total of four fasteners.

The deck has a first side lap extending transverse to the first and second end supports along one edge of the deck. The deck has a second side lap extending transverse to the end supports along an opposite edge of the deck. The deck has one of the plurality of low flutes adjacent the first side lap and another of the plurality of low flutes adjacent the second side lap. Each of the low flutes adjacent the side laps has one of the plurality of third fasteners affixed thereto. The deck also has a low flute on a side of the flute adjacent to the first side lap which has no fasteners therein. The deck has a low flute on a side of the low flute adjacent the second side lap which has no fastener from the plurality of third fasteners therein.

The deck has a plurality of high flutes that are positioned respectively between adjacent low flutes of the plurality of low flutes. The plurality of high flutes have no fasteners therein. Each of the plurality of first, second and third fasteners is a pin. Alternatively, each of the first, second and third fasteners is an arc spot weld.

In the building panel assembly of the present invention, there can be a second deck that is affixed in edge-to-edge relationship to the first deck. The second deck has a configuration identical to that of the first deck. The first side lap of the first deck is affixed to the first side lap of the second deck. The side laps of the first and second decks are joined together by a penetrating clinch connections. Alternatively, the side laps can be joined together by welding. The second deck also resides on the first and second end supports and the intermediate supports.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is an upper perspective view of the building panel assembly of the present invention.

FIG. 2 is an end view of the building panel assembly of the present invention having a pair of decks joined together.

FIG. 3 is a detailed view showing the joining of side laps together in the building panel assembly of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, there is shown the building panel assembly 10 in accordance the teachings of the present invention. The building panel assembly 10 includes a first end support 12, a second end support 14 and an intermediate support 16. The second end support 14 is in generally spaced parallel relationship to the first end support 12. The intermediate support 16 is positioned between the first end support 12 and the second end support 14 in parallel spaced relationship thereto. A deck 18 is positioned on the first end support 12 and the second end support 14 and the intermediate support 16. The deck 18 has a plurality of low flutes 20 extending in parallel relationship to each other and extending across the deck in transverse relation to the first end support 12, the second end support 14 and the intermediate support 16. As can be seen, there are total of seven low flutes extending across the deck section 18. High flutes 22 are positioned between adjacent low flutes 20. The high flutes 22 have a generally flat top surface 24 which is in an elevated position of the end supports 12 and 14 and the intermediate support 16. The top surfaces 24 of the high flutes 22 are arranged generally coplanar with each other. A first side lap 26 is formed along one edge of the deck 18 adjacent to one of the low flutes 20. A second side lap 28 extends along the opposite edge of the deck 18. The first side lap 26 is in the form of an inverted U-shaped envelope. The second side lap 28 is an upright member. The side laps 26 and 28 allow the deck 18 to be properly joined in edge-to-edge relationship with an adjacent deck, as described hereinafter in association with FIG. 2.

A plurality of first fasteners 30 are affixed in the low flutes 20 of the deck 18. The plurality of first fasteners 30 serve to secure the deck 18 to the first end support 12. The first fasteners 30 are affixed in each and every one of the low flutes 20 so as to provide a secure connection with the top surface 32 of the first end support 12. A plurality of second fasteners 34 are affixed in the low flutes 20 of the deck 18. This plurality of second fasteners 34 serves to secure the opposite side of the deck 18 to the second end support 14. The second fasteners 34 are affixed in each and every one of the low flutes 20 of the deck 18. A plurality of third fasteners 36 are affixed in the low flutes 20 of the deck so as to secure the deck 18 to the intermediate support 16. As can be seen, the number of first fasteners 30 totals seven fasteners. The number of second fasteners 34 totals seven fasteners. The number of third fasteners 36 totals four fasteners. Ultimately, in the concept of the present invention, the number of third fasteners 36 should be less than the number of first fasteners 30 or the number of second fasteners 34. The third fasteners 36 are positioned in alternating low flutes 20. In other words, one of the third fasteners 36 is positioned adjacent to the side lap 26. Another of the third fasteners 36 is positioned in the low flutes 20 adjacent to the second side lap 28. The low flutes 20 adjacent to the low flute 20 that is next to the side lap 26 is free of any third fasteners 36. Similarly, the low flute adjacent to the low flute 20 that is next to the second side lap 28 is free of any third fasteners 36. The central low flute 20 is also free of any third fasteners 36.

As used herein, the first fasteners 30, the second fasteners 34 and the third fasteners 36 can be pins or arc spot welds. Each of the end supports 12 and 14 is an I-beam. Similarly, the intermediate support 16 is an I-beam. Each of the fasteners 30, 34 and 36 secures the deck 18 to the top surface of each of the supports 12, 14 and 16.

The building panel assembly 10 of the present invention is the result of testing. This testing indicated that the number of fasteners to the intermediate support 16 are not a source of diaphragm failure in shear for the building panel. Unlike the prior art, the present invention does not utilize the same number of third fasteners 36 as compared with first fasteners 30 and second fasteners 34. The testing shows that the reduction of the number of third fasteners 36 does not reduce the shear capacity of the deck 18.

The following table illustrates a comparison of shear performance between deck assemblies of prior art and assemblies of the present invention. Prior art assemblies have the number of third fasteners 36 equal to the number of first fasteners 30 and second fasteners 34 (shear values in the column labeled “Shear 2”). The present invention assemblies have the number of third fasteners 36 less than the number of first fasteners 30 and second fasteners 34 (shear values in the column labeled “Shear 1”).

TABLE I Comparison of Shear Performance Shear 2 Difference Test Fastener Gage Shear 1 (kip/ft) (kip/ft) (%) B1-04 #12-14 16 2.41 2.42 −1 H1-07 X ENP 19 16 7.08 7.14 −1 H2-07 X ENP 19 18 4.21 3.23 30 H3-07 X ENP 19 18 3.86 4.48 −14 H4-07 X EDNK22 22 1.37 1.43 −4 H5-07 X EDN 19 22 1.81 1.88 −3 P1-07 K64 16 6.70 6.19 8 P2-07 SDK63 20 3.53 3.85 −8 P2-07 SDK61 20 1.83 1.87 −2 W1-07 Arc Spot Weld 18 4.58 3.85 19 W2-07 Arc Spot Weld 16 5.42 5.58 −3

The “Test” column identifies a number of different tests that were performed using decks 18 having low flutes 20 and upper flutes 22 as described above. The decks 18 in each test had a length of thirty-six inches. Each deck also had a gage, the value being indicated in the “Gage” column, ranging from 16-22. The different varieties of fasteners used to fix the decks 18 to the support beams for purposes of testing are indicated in the “Fastener” column. The last two rows indicate that the deck 18 was affixed to the supports 12, 14, and 16 by arc spot welds and not fasteners.

Shear 1 is the shear tolerance of the assembly of the present invention. Shear 2 is the shear tolerance of the prior art assembly. The value of Shear 1 is the shear tolerance of the deck 18 fastened to supports 12, 14, and 16 using four third fasteners 36 to fix the deck 18 to intermediate support 16, and seven first and second fasteners 30 and 34 to fix the deck 18 to each of first and second supports 12 and 14, respectively. The value of Shear 2 is the shear tolerance of the deck 18 fastened to supports 12, 14, and 16 using seven third fasteners 36 to fix the deck 18 to intermediate support 16, and seven first and second fasteners 30 and 34 to fix the deck 18 to each of first and second supports 12 and 14, respectively.

As can be seen in Table I, the performance of the present invention is almost identical to the performance of the prior art. That is, when the differences between Shear 1 and Shear 2 are compared, using four third fasteners 36 decreases the shear strength of the deck 18 by only a small percentage, ranging from −1% to −14%. In tests “H2-07” and “W1-07,” the shear tolerance is actually increased by using only four third fasteners 36, valuing 30% and 19%, respectively. The results in Table I above show the assembly of the deck 18 onto the supports 12, 14 and 16 according to the present invention is just as strong, if not stronger, and simpler, requires fewer fasteners, and requires less labor in installation than prior art assemblies.

FIG. 2 is an end view of the building panel assembly 10. In FIG. 2, there is illustrated the first deck 18 and a second deck 40. The second deck 40 has an identical configuration to that of the first deck 18. It can be seen that the first deck 18 and the second deck 40 are supported on the first end support 12. The first deck 18 has a plurality of low flutes 20 that are secured by fasteners 30 to the top surface 32 of the first end support 12. High flutes 22 extend between adjacent low flutes 20. As can be seen, the top surface 24 of the high flutes 22 forms a generally planar surface. The side lap 26 is in the form of a U-shaped envelop at one edge of the first deck 18. The second side lap 28 is located at the opposite edge of the deck 18. The second side lap 28 is in the form of an upright member. The second deck 40 also includes a first side lap 42 which extends over and is joined to the side lap 28 of the first deck 18. The side lap 42 is in the form of a U-shaped envelop identical to that of the side lap 26 of the first deck 18. By placing the interior of the first side lap 42 of the second deck 40 over the upright member of the second side lap 28 of the first deck 18, the decks 18 and 40 can be joined in edge-to-edge relationship with each other.

The second deck 40 also includes a plurality of low flutes 44 that are joined by first fasteners 30 to the top surface 32 of first end support 12. The second deck 40 also includes high flutes 46 extending between adjacent low flutes 44. A second side lap 48 is formed at the edge of the second deck 40 opposite to the first side lap 42. The second side lap 48 is in the form of an upright member suitable for joining to the U-shaped envelope of a side lap of another panel.

In FIG. 2, it can be seen that the first fasteners 30 serve to secure the low flutes of the decks 18 and 40 to the top surface 32 of first end support 12. The first fasteners 30 are illustrated in the nature of pins. However, arc spot welds would also serve the same purpose.

FIG. 3 is a perspective view showing the particulars of joining the side laps of corresponding decks 200 and 209 together. As can be seen in FIG. 3, the deck 200 has a low flute 201 and a high flute 203 formed thereon. A low flute 205 is formed adjacent to the side lap 207. Side lap 207 is in the nature of an upright member. The deck 209 has a low flute 211 on one side of the high flute 213 and a low flute 221 on an opposite side of the high flute 213. Low flute 221 is adjacent to the side lap 223. Side lap 223 is in the nature of a U-shaped envelope that overlies the upright member of the side lap 207 of the deck 200.

In order to effect the joining of the decks 200 and 209 together at the side laps 207 and 223, a punch tool is applied so as to create the punches 206, 208 and 210. The punches 206, 208 and 210 assure a proper connection between the decks 200 and 209. The formation of these triangular-shaped cuts associated with punches 206, 208 and 210 will prevent any lateral shifting of the decks 200 and 209 with respect to each other. Also, the punches 206, 208 and 210 will establish a suitable connection to prevent the sections 200 and 209 from pulling away from each other. As such, this method of crimping and joining, in the nature of penetrating clinch connections, assures a proper connection between the adjacent deck sections.

The foregoing disclosure and description of the invention is illustrative and explanatory thereof. Various changes in the details of the illustrated construction can be made within the scope of the appended claims without departing from the true spirit of the invention. The present invention should only be limited by the following claims and their legal equivalents. 

1. A building panel assembly comprising: a first end support; a second end support in generally spaced parallel relationship to said first end support; an intermediate support positioned between said first and second end supports and in spaced parallel relationship thereto; a deck positioned on said first and second end supports and said intermediate support, said deck having a plurality of low flutes extending in parallel relationship to each other and extending across said deck in transverse relationship to said first and second end supports; a plurality of first fasteners affixed in said plurality of low flutes of said deck, said plurality of first fasteners securing said deck to said first end support; a plurality of second fasteners affixed in said plurality of low flutes of said deck, said plurality of second fasteners securing said deck to said second end support; and a plurality of third fasteners affixed in said plurality of low flutes of said deck, said plurality of third fasteners securing said deck to said intermediate support, said plurality of third fasteners being of a number of fasteners less than a number of said plurality of first fasteners.
 2. The assembly of claim 1, said plurality of first fasteners affixed in each and every one of said plurality of low flutes of said deck, said plurality of second fasteners affixed in each and every one of said plurality of low flutes of said deck.
 3. The assembly of claim 1, said plurality of third fasteners being only in every other low flute of said plurality of low flutes in said deck.
 4. The assembly of claim 1, said deck having seven low flutes formed therein, said plurality of third fasteners being four fasteners.
 5. The assembly of claim 1, said deck having a first side lap extending transverse to said first and second end supports along one edge of said deck, said deck having a second side lap extending transverse to said first and second end supports along an opposite edge of said deck.
 6. The assembly of claim 5, said deck having a one of said plurality of low flutes adjacent said first side lap and another of said plurality of low flutes adjacent said second side lap, each of the low flutes adjacent the side laps having one of said plurality of third fasteners affixed thereto.
 7. The assembly of claim 6, said deck having a low flute of said plurality of low flutes on a side of the low flute adjacent said first side lap which has no fastener of said plurality of third fasteners therein, said deck having a low flute of said plurality of low flutes on a side of the low flute adjacent said second side lap which has no fastener of said plurality of third fasteners therein.
 8. The assembly of claim 1, said deck having a plurality of high flutes positioned respectively between adjacent low flutes of said plurality of low flutes, said plurality of high flutes having no fasteners therein.
 9. The assembly of claim 1, each of said plurality of first fasteners and said plurality of second fasteners and said plurality of third fasteners being a pin.
 10. The assembly of claim 1, each of said plurality of first fasteners and said plurality of second fasteners and said plurality of third fasteners being an arc spot weld.
 11. A building panel assembly comprising: a first end support; a second end support in generally spaced parallel relationship to said first end support; an intermediate support positioned between said first and second end supports and in spaced parallel relationship thereto; a first deck positioned on said first and second end supports and on said intermediate support, said first deck having a plurality of low flutes extending in parallel relationship to each other and extending across said first deck in transverse relationship to said first and second end supports; a second deck positioned on said first and second end supports and on said intermediate support, said second deck having a plurality of low flutes extending in parallel relationship to each other and extending across said second deck in transverse relationship to said first and second end supports, said second deck in edge-to-edge relationship to said first deck; a plurality of first fasteners affixed in the low flutes of said first and second decks, said plurality of first fasteners securing said first and second decks to said first end support; a plurality of second fasteners affixed in the low flutes of said first and second decks, said plurality of second fasteners securing said first and second decks to said second end support; and a plurality of third fasteners affixed in the low flutes of said first and second decks, said plurality of third fasteners securing said first and second decks to said intermediate support, said plurality of third fasteners being of a number of fasteners less than a number of said plurality of first fasteners.
 12. The assembly of claim 11, said first deck having a first side lap extending transverse to said first and second end supports along one edge of said first deck, said first deck having a second side lap extending transverse to said first and second end supports along an opposite edge of said deck, said second deck having first side lap extending transverse to said first and second end supports along one edge of said second deck, said second deck having a second side lap extending transverse to said first and second end supports along an opposite edge of said second deck.
 13. The assembly of claim 12, said first side lap of said first deck affixed to said first side lap of said second deck by a plurality of penetrating clinch connections.
 14. The assembly of claim 12, said first side lap of said first deck affixed to said first side lap of said second deck by welding.
 15. The assembly of claim 11, said plurality of first fasteners affixed in each and every one of said plurality of low flutes of said first and second decks, said plurality of second fasteners affixed in each and every one of said plurality of low flutes of said first and second decks.
 16. The assembly of claim 11, said plurality of third fasteners being only in every other low flute of said plurality of low flutes of said first and second decks.
 17. The assembly of claim 11, said first deck having seven low flutes formed therein, said plurality of third fasteners having a four fasteners affixed to said plurality of low flutes of said first deck.
 18. The assembly of claim 12, said first deck having one of said plurality of low flutes adjacent said first side lap thereof and another of said plurality of low flutes adjacent said second side lap thereof, each of the low flutes adjacent the side laps of said first deck having one of said plurality of third fasteners affixed thereto.
 19. The assembly of claim 11, each of said plurality of first fasteners and said plurality of second fasteners and said plurality of third fasteners being a pin.
 20. The assembly of claim 11, each of said plurality of first fasteners and said plurality of second fasteners and said plurality of third fasteners being an arc spot weld. 